LMS Conference April 18 th , 2007 Institute Structural Durability and System Reliability S. Weiland Institute Structural Durability and System Reliability Page 2 Contents Introduction Guideline ECE R 55.01 in Comparison with Customer Usage Standardized Load Sequence CARLOS TC Usage of CARLOS TC at Fraunhofer LBF Control and Monitoring of test Summary and Perspective Page 3 CARLOS TC (CAR LOading Standard, Trailer Coupling) Consortium Participants Car OEMs: Adam Opel AG Audi AG BMW Group DaimlerChrysler AG Ford-Werke AG Porsche AG Skoda AG Volkswagen AG Volvo Car Technical Control Boards: RWTV Fahrzeug GmbH, Essen TV Automotive, Mnchen Suppliers: AL-KO GmbH Bosal Research Karmann GmbH MVG mbH Oris Fahrzeugteile Hans Riehle GmbH PD&E Automotive Solutions Magna Steyr Fahrzeugtechnik AG & Co KG Westfalia Automotive GmbH & Co KG Research Institutes: Fraunhofer Institute for Structural Durability LBF (project manager) KATECH (Korea Automotive Technology Institute) Page 4 Introduction Trailer coupling devices (TCD) are safety-critical components Test for homologation of TCDs according to ECE R 55.01 Car manufacturers are testing with service loads similar to customer usage Challenges: - New testing procedure which is accepted by OEMs and suppliers - Implementation of new testing procedure in the guideline ECE R 55.01 Page 5 Comparison of Guideline ECE R 55.01 and Customer Usage Tests for the homologation of TCDs according to ECE R 55.01 are performed with - sinusoidal loading !1-dimensional loading (1-D) !constant amplitudes (CA) !no mean load (R = -1) !without car-body F Fatigue relevant local stresses and strains on TCDs are depending on - service loads !3-dimensional loading (3-D) !variable amplitudes (VA) !variable mean loads (R ! -1) !with car-body Page 6 Uni- & Multiaxial Load Cycles to Failure Uni- & Multiaxial Load: - different cycles to failure with the same force amplitudes Cycles to Failure N M a x i m u m
F o r c e
F m a x uniaxial load fatigue life curve uniaxial load fatigue life curve multiaxial load; partly correlated phase multiaxial load; partly correlated phase Page 7 Load Cycles to Failure Points of Crack Initiation T o r s i o n a l M o m e n t Constant Amplitude Testing Type of Failure CA-Testing: - type of failure depends on load amplitude Page 8 Mean Load - Cycles to Failure Cycles to Failure N S t r e s s
A m p l i t u d e
" a axial loading Strain Amplitude " a time R = " u / " o 400 N/mm 2 Mean Load: - different cycles to failure with same load amplitude R = # R = -1 Page 9 Currently used guideline ECE R 55.01 The ECE R 55.01 guideline: - sinusoidal loading !1-dimensional loading (1-D) !constant amplitudes (CA) !no mean load (R = -1) !Durability assessment is critical with respect to: - type of failure - cycles to failure F Improvement: Testing procedure oriented on 3-D service loads captures failure types and life time typical in service. Page 10 Derivation of a Testing Procedure based on Service Loads Input: 42 verification tests / measurements from OEMs Signal analysis: verifications, normalizations, correlations, load spectra Derivation of 3 Modules: based on representative 22 load segments Testing Procedure: damage sums, duration (< 150 h), frequencies, max. amplitudes CARLOS TC: duration: ~ 92 h, module mix: 10*[5*(10*M1+M2)+M3] Page 11 CARLOS TC Distributions of Test-Modules M1, M2, M3 and whole Test-Procedure: 10*(5*(10*M1+M2)+M3) 1 10 100 1000 10000 100000 1E+06 1E+07 -2 -1.5 -1 -0.5 0 0.5 1 1.5 2 Longitudinal Force F x Number of Level Crossings M1, 12% omission M2, 12% omission M3, 12% omission CARLOS TC Test modules 1, 2 and 3 derived from 22 load segments. Module 1: incl. moderate service loads Module 2: incl. severe service loads Module 3: incl. exceptional loads F o r c e
F x /
D Page 12 Current EC Homologation Test ECE R 55.01 (1-D, CA) and CARLOS Trailer Coupling (Realistic loading: 3-D, VA) [kN] ) m m ( m m g D T V T V $ % % & m V = vehicle mass m T = trailer mass ECE R 55.01 ECE R 55.01 ECE R 55.01 F x ECE R 55.01 F z Number of load cycles F o r c e
( a m p l i t u d e )
/
D CARLOS TC F z CARLOS TC F y CARLOS TC F x Page 13 0.02 0.04 0.06 0.08 0.1 0.2 0.4 0.6 0.8 1 2 0.003 0.13 0.5 1 2 5 10 20 30 40 50 60 70 80 90 95 98 99 99.5 99.87 99.997 P r o b a b i l i t y
% Comparison of Damage-Equivalent Amplitudes ECE R 55.01, Scatter Bands of 42 Verification Tests, CARLOS TC Damage Equivalent Amplitude F x /D, F y /D, F z /D P r o b a b i l i t y ,
% Calibration for test with bodies CARLOS TC (Fx CARLOS TC (Fy CARLOS TC (Fz 94/20/EC (Fx) 94/20/EC (Fz) Fx, Verific Test Fy, Verific Test Fz, Verific Test ECE R 55.01 (Fx) ECE R 55.01 (Fz) Page 14 CARLOS TC Rainflow Matrices for Whole Test (Car Body) F x F y F z Number of Cycles F r o m
B i n ,
F o r c e / D To Bin, Force/D Longitudinal Force Lateral Force Vertical Force Page 15 CARLOS TC Display of Fictitious Damage Values Using the Load Influence Sphere 0.1 0.5 1.0 L a t e r a l
F o r c e V e r t i c a l
F o r c e Longitudinal Force Longitudinal Force Lateral Force Normalized fictitious damage value (S-N curve: k = 5) V e r t i c a l
F o r c e Page 16 Ratio of Fictitious Damage Values D fict - CARLOS TC vs. ECE R 55.01 CTC115 / ECE R 55.01 [%] >1000 400 200 100 50 25 <10 y z x z 01 . 55 _ _ ' ' ' & R ECE fict TC CARLOS fict rel D D D k = 5 Miner elementary F x , F z (M y ): ECE R 55.01 is much more severe than CARLOS TC F y (M x , M z ): CARLOS TC is much more severe than ECE R 55.01 uni-axial testing procedure leads to unrealistic damage distribution D rel Page 17 Multiaxial Test-Rig for Trailer Coupling Devices of Passenger Cars and Light Trucks at Fraunhofer LBF (D max =17kN) Page 18 Spring/Damper Replacements Page 19 Iteration Process at Test Rig (1) F o r c e
[ k N ] Time [s] Desired Signal: Vertical Force F z Response Signal: Vertical Force F z Iteration Number S t a t i s t i c s [ % ] 1-Damage_Response, 3, F x 2-Stats_ResponseMax, 3, F x 3-Stats_ResponseMin, 3, F x 4-Stats_RMSError, 3, F x 4 3 2 1 0 0 % 00 % Page 20 Iteration Process Test Rig Using (2) Frequency [Hz] P o w e r - S p e c t r a l - D e n s i t y [ k N 2 / H z ] Desired Signal: Vertical Force F z Response Signal: Vertical Force F z F o r c e
[ k N ] Cycles Desired Signal: Vertical Force F z Response Signal: Vertical Force F z Page 21 Monitoring of Tests Results: 100 100 100 112,26 102,36 103,58 0 20 40 60 80 100 120 F x F y F z [ % ] Damage of desired signal Damage of response signal D a m a g e [ % ] Page 22 Test Results Failure at Rear Light House Page 23 Test Results Failure at Boot Bottom Page 24 Test Results Failure at Wheelhouse Page 25 CARLOS TC Summary and Perspective Development of safety-critical components requires consideration of service loading Legal requirement ECE R 55.01 does not take into account current durability sign-off tests of car manufacturers (service loads) CARLOS TC: - considers 3-D service loads - failures are similar to failures at proving-ground - reduces development loops with physical prototypes Planned: integration of CARLOS TC in ECE R 55.01 LBF provides test facility according to CARLOS TC requirements Page 26 Used Software-Tools LMS.Tecware: signal processing, rainflow counting, calculation of damage impact LMS.Tecware / RainEdit: editing of rainflow matrices, super-positioning of rainflow matrices LMS.Tecware / CombiTrack: schedule of load modules (optimized histogram) LMS.Falancs: fatigue assessment based on FEA (stress approach) Page 27 Thank you for your kind attention!